Fabricated vehicle wheel and method for producing same

ABSTRACT

This invention relates to an improved fabricated vehicle wheel. According to one embodiment of the invention, the fabricated vehicle wheel includes a wheel rim having a plurality of holes formed therein; a wheel disc having a central mounting surface and a plurality of outwardly extending spokes, each of the spokes having at least one hole formed therein; at least one rim to disc interface area provided along each of the spokes wherein some portion of a surface of the rim and some portion of a surface of the spoke contact one another; an adhesive deposited in at least some portion of the rim to disc interface area; and at least one fastener extending through the holes of the rim and the spokes to secure the rim and disc together.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of PCT/US02/17534, filed May31, 2002, which claims the benefit of U.S. Provisional Application Ser.No. 60/338,531, filed Oct. 30, 2001, and U.S. Provisional ApplicationSer. No. 60/338,539, filed Oct. 30, 2001.

BACKGROUND OF THE INVENTION

[0002] This invention relates in general to vehicle wheels and inparticular to an improved fabricated vehicle wheel.

[0003] A conventional fabricated vehicle wheel is typically of atwo-piece construction and includes an inner disc and an outer “full”rim. The disc can be cast, forged, or fabricated from steel, aluminum,or other alloys, and includes an inner annular wheel mounting portionand an outer annular portion. The wheel mounting portion defines aninboard mounting surface and includes a center pilot or hub hole, and aplurality of lug receiving holes formed therethrough for mounting thewheel to an axle of the vehicle. The rim is fabricated from steel,aluminum, or other alloys, and includes an inboard tire bead seatretaining flange, an inboard tire bead seat, an axially extending well,an outboard tire bead seat, and an outboard tire bead seat retainingflange. In some instances, a three-piece wheel construction having amounting cup secured to the disc is used. In both types ofconstructions, the outer annular portion of the disc is typicallysecured to the rim by welding.

[0004] A full face fabricated wheel is distinguished from other types offabricated wheels by having a one-piece wheel disc construction. Inparticular, the full face wheel includes a “full face” disc and a“partial” rim. The full face disc can be formed cast, forged, orfabricated from steel, aluminum, or other alloys. The full face discincludes an inner annular wheel mounting portion and an outer annularportion which defines at least a portion of an outboard tire bead seatretaining flange of the wheel. The wheel mounting portion defines aninboard mounting surface and includes a center pilot or hub hole, and aplurality of lug receiving holes formed therethrough for mounting thewheel to an axle of the vehicle. The partial rim is fabricated fromsteel, aluminum, or other alloys, and includes an inboard tire bead seatretaining flange, an inboard tire bead seat, an axially extending well,and an outboard tire bead seat. In some instances, the outboard tirebead seat of the rim and the outer annular portion of the disc cooperateto form the outboard tire bead seat retaining flange of the full facewheel. In both types of constructions, the outboard tire bead seat ofthe rim is positioned adjacent the outer annular portion of the disc anda weld is applied to secure the rim and the disc together.

[0005] A fabricated vehicle wheel is shown in U.S. Pat. No. 6,042,194 toFitz et al. As shown in the embodiment illustrated in FIGS. 4 and 5 ofthe Fitz et al. patent, the wheel includes an outer full rim and aninner one piece disc having a plurality of spoke members. Each spokemember includes an outer end which is welded to the rim to produce thevehicle wheel. The Fitz et al. patent discloses other embodiments of awheel construction having individual spoke members which are secured tothe rim in a similar manner.

SUMMARY OF THE INVENTION

[0006] This invention relates to an improved fabricated vehicle wheel.According to one embodiment of the invention, the fabricated vehiclewheel includes a wheel rim having a plurality of holes formed therein; awheel disc having a central mounting surface and a plurality ofoutwardly extending spokes, each of the spokes having at least one holeformed therein; at least one rim to disc interface area provided alongeach of the spokes wherein some portion of a surface of the rim and someportion of a surface of the spoke contact one another; an adhesivedeposited in at least some portion of the rim to disc interface area;and at least one fastener extending through the holes of the rim and thespokes to secure the rim and disc together.

[0007] According to another embodiment of the invention, the vehiclewheel includes a wheel rim having a plurality of holes formed therein; awheel disc having a central mounting surface and a plurality ofoutwardly extending spokes, each of the spokes having at least two holesformed therein; at least one rim to disc interface area provided alongeach of the spokes wherein some portion of a surface of the rim and someportion of a surface of the spoke contact one another; and a fastenerextending through each of the at least two holes of each of the spokesand through an associated at least two holes of the plurality of holesof the rim to secure the rim and disc together.

[0008] According to yet another embodiment of the invention, the vehiclewheel includes a wheel rim having a plurality of holes formed therein; awheel disc having a central mounting surface and a plurality ofoutwardly extending spokes, each of the spokes having at least one holeformed therein; at least one rim to disc interface area provided alongeach of the spokes wherein some portion of a surface of the rim and someportion of a surface of the spoke contact one another; and at least onefastener extending through the holes of the rim and the spokes to securethe rim and disc together; wherein the mounting surface includes asection which extends between each pair of the spokes, the sectionincluding a first wall and a second wall, the first wall extendinggenerally radially outwardly at an angle in the range from about 5degrees to about 85 degrees with respect to the back wall of themounting surface, the second wall extending at an angle in the rangefrom about 0 degrees to about 30 degrees with respect to the back wallof the mounting surface.

[0009] A method for producing an embodiment of a fabricated vehiclewheel in accordance with this invention comprises the steps of: (a)providing a wheel rim defining a rim axis and including an inboard tirebead seat retaining flange, an inboard tire bead seat, a generallyaxially extending well portion, an outboard tire bead seat and anoutboard tire bead seat retaining flange; (b) providing a wheel discblank; (c) subjecting the wheel disc blank to a metal forming operationto produce a partially formed wheel disc having a plurality of outwardlyextending spoke portions which are spaced circumferentially about thedisc blank; (d) subjecting the partially formed wheel disc to a metalforming operation to produce a wheel disc preform, the wheel discpreform including an inner mounting portion, a plurality of outer spokeportions, and an intermediate spoke portion defined in the regionbetween the inner mounting portion and outer spoke portions, theintermediate spoke portion including a plurality of generally globeshaped spoke portions; (e) subjecting the wheel disc preform to one ormore metal forming operations to produce a finished wheel disc, thefinished wheel disc including a centrally located wheel mounting surfaceand a plurality of outwardly extending spokes; and (f) securing thewheel disc and the wheel rim together to produce the fabricated vehiclewheel.

[0010] Other advantages of this invention will become apparent to thoseskilled in the art from the following detailed description of thepreferred embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is a front view of a first embodiment of a fabricatedvehicle wheel in accordance with the present invention.

[0012]FIG. 2 is a sectional view of the vehicle wheel taken along line2-2 of FIG. 1.

[0013]FIG. 3 is an enlarged view of a portion of the vehicle wheelillustrated in FIGS. 1 and 2 showing a first embodiment of a method forjoining the wheel rim and the wheel disc together in accordance with thepresent invention.

[0014]FIG. 4 is an enlarged view showing a second embodiment of a methodfor joining the wheel rim and the wheel disc together in accordance withthe present invention.

[0015]FIG. 5 is an enlarged view showing a third embodiment of a methodfor joining the wheel rim and the wheel disc together in accordance withthe present invention.

[0016]FIG. 6 is an enlarged view showing a fourth embodiment of a methodfor joining the wheel rim and the wheel disc together in accordance withthe present invention.

[0017]FIG. 7 is a view of a first alternate embodiment of a fastenerthat can be used to join the wheel rim and the wheel disc together inaccordance with the present invention.

[0018]FIG. 8 is a view of a second alternate embodiment of a fastenerthat can be used to join the wheel rim and the wheel disc together inaccordance with the present invention.

[0019]FIG. 9 is a view of a third alternate embodiment of a fastenerthat can be used to join the wheel rim and the wheel disc together inaccordance with the present invention.

[0020]FIG. 10 is a view of a fourth alternate embodiment of a fastenerthat can be used to join the wheel rim and the wheel disc together inaccordance with the present invention.

[0021]FIG. 11 is a front view illustrating a second embodiment of afabricated vehicle wheel in accordance with the present invention.

[0022]FIG. 12 is a sectional view of the vehicle wheel taken along line12-12 of FIG. 11.

[0023]FIG. 13 is an enlarged view of a portion of the vehicle wheelillustrated in FIGS. 11 and 12.

[0024]FIG. 14 is a front view of a third embodiment of a fabricatedvehicle wheel in accordance with the present invention.

[0025]FIG. 15 is a sectional view of the vehicle wheel taken along line15-15 of FIG. 14.

[0026]FIG. 16 is a sectional view of the vehicle wheel taken along line16-16 of FIG. 14.

[0027]FIG. 17 is an enlarged view of a portion of the vehicle wheelillustrated in FIGS. 14 and 15.

[0028]FIG. 18 is an enlarged view of a portion of a fourth embodiment ofa fabricated vehicle wheel in accordance with the present invention.

[0029]FIG. 19 is a sectional view of the vehicle wheel taken along line19-19 of FIG. 18.

[0030]FIG. 20 is a sectional view of the vehicle wheel taken along line20-20 of FIG. 18.

[0031]FIG. 21 is a view of a fifth alternate embodiment of a fastenerthat can be used to join the wheel rim and the wheel disc together inaccordance with the present invention.

[0032]FIG. 22 is a view of a sixth alternate embodiment of a fastenerthat can be used to join the wheel rim and the wheel disc together inaccordance with the present invention.

[0033]FIG. 23 is a view of a fifth embodiment of a fabricated vehiclewheel in accordance with the present invention.

[0034]FIG. 24 is a view of the wheel disc illustrated in FIG. 23.

[0035]FIG. 25 is a sectional view of a portion of the vehicle wheelillustrated in FIG. 23.

[0036]FIG. 26 is a view of a sixth embodiment of a fabricated vehiclewheel in accordance with the present invention.

[0037]FIG. 27 is a view of the wheel disc illustrated in FIG. 25.

[0038]FIG. 28 is a plan view showing the initial stamping of a sheet ofmetal material in order to produce a wheel disc blank for use inconstructing the first embodiment of the vehicle wheel shown in FIGS. 1and 2 of this invention.

[0039]FIG. 28A is a sectional view of the wheel disc blank taken alongline 28A-28A of FIG. 28.

[0040]FIG. 29 is a plan view showing the stamping of the wheel discblank in order to produce a finished wheel disc blank in accordance withthis invention.

[0041]FIG. 29A is a sectional view of the finished wheel disc blanktaken along line 29A-29A of FIG. 29.

[0042]FIG. 30 is a plan view showing the stamping of the finished wheeldisc blank in order to produce a bubble shaped wheel disc preform inaccordance with this invention.

[0043]FIG. 30A is a sectional view of the bubble shaped wheel discpreform taken along line 30A-30A of FIG. 30.

[0044]FIG. 31 is a plan view showing the stamping of the bubble shapedwheel disc preform in order to produce a partially formed wheel disc inaccordance with the present invention.

[0045]FIG. 31A is a sectional view of the partially formed wheel disctaken along line 31A-31A of FIG. 31.

[0046]FIG. 32 is a plan view showing the restriking of the wheel disc inorder to produce a wheel disc in accordance with the present invention.

[0047]FIG. 32A is a sectional view of the wheel disc taken along line32A-32A of FIG. 32.

[0048]FIG. 33 is a plan view showing the piercing of the windows and thehub hole and the trimming of the outer ends of the wheel disc in orderto produce a wheel disc in accordance with the present invention.

[0049]FIG. 33A is a sectional view of the wheel disc taken along line33A-33A of FIG. 33.

[0050]FIG. 34 is a plan view showing the extruding of the wheel disc inorder to produce a wheel disc in accordance with the present invention.

[0051]FIG. 34A is a sectional view of the wheel disc taken along line34A-34A of FIG. 34.

[0052]FIG. 35 is a plan view showing the piercing of the lug boltreceiving holes and the countersinking of hub hole in the wheel disc inorder to produce a finished wheel disc in accordance with the presentinvention.

[0053]FIG. 35A is a sectional view of the finished wheel disc takenalong line 35A-35A of FIG. 35.

[0054]FIG. 36 is a block diagram illustrating a sequence of steps forproducing a full face fabricated vehicle wheel in accordance with thepresent invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0055] Referring now to the drawings, FIGS. 1 through 3 illustrate afirst embodiment of a fabricated vehicle wheel, indicated generally at10, produced in accordance with the present invention. The vehicle wheel10 produced according to this invention is illustrated as being afabricated “bead seat attached” vehicle wheel. The fabricated bead seatattached vehicle wheel 10 includes a full wheel rim 20 and an innerwheel disc 40 which are constructed and joined together in accordancewith the present invention. The vehicle wheel 10 defines a horizontal orlongitudinal vehicle wheel axis X. Although the present invention isillustrated and described in conjunction with the particular vehiclewheel constructions disclosed herein, it will be appreciated that theinvention can be used in conjunction with other types of vehicle wheelconstructions. For example, the vehicle wheel can be a “drop center” or“well attached” vehicle wheel (such as shown in FIG. 3 of U.S. Pat. No.5,188,429 to Heck et al. and/or also as shown in FIGS. 23-27 anddescribed hereinbelow), the disclosure of this patent incorporatedherein by reference.

[0056] The wheel rim 20 is a fabricated rim formed from a suitablematerial, such as for example, steel, aluminum or alloys thereof,magnesium, or titanium. The wheel rim 20 includes an inboard tire beadseat retaining flange 22, an inboard tire bead seat 24, a generallyaxially extending well 26, an outboard tire bead seat 28, and anoutboard tire bead seat retaining flange 30. The well 26 includes anouter surface 26A and the outboard tire bead seat 28 includes an outersurface 28A and an inner surface 28B. The outboard tire bead seat 28further includes a plurality of holes 28C (best shown in FIG. 3), formedtherein. As will be discussed below, the holes 28C are formed by asuitable process, such as for example, by piercing, drilling, or lasercutting.

[0057] The wheel disc 40 is forged, cast, fabricated, or otherwiseformed from a suitable material, such as for example, steel, aluminum oralloys thereof, steel, magnesium, or titanium. The wheel disc 40includes a generally centrally located wheel mounting surface or portion42 and a plurality of outwardly extending spokes 44. In the illustratedembodiment, the disc 40 includes six of such spokes 44 which are shownas being formed integral with the wheel mounting surface 42.Alternatively, the number and/or the construction of the spokes 44 canbe other than illustrated if so desired. For example, the vehicle wheel10 can include less than six spokes 44 or more than six spokes 44 and/orthe spokes 44 can be formed separate from the wheel mounting surface 42of the disc 40 and joined thereto by a suitable method.

[0058] The wheel mounting surface 42 is provided with a centrallylocated pilot aperture 42A and a plurality of lug bolt receiving holes42B circumferentially spaced around the pilot aperture 42A. In theillustrated embodiment, the wheel mounting surface 42 includes six ofsuch lug bolt receiving holes 42B which are preferably provided in thewheel mounting surface 42 “in line” with a respective one of each of thespokes 44. Alternatively, the number and/or the location of the lug boltreceiving holes 42B can be other than illustrated if so desired. The lugbolt receiving holes 42B receive lug bolts (not shown) and nuts (notshown) for securing the vehicle wheel 10 on an axle (not shown) of avehicle.

[0059] The mounting surface 42 further includes a plurality of“strengthening” ribs 42C provided therein. In the illustratedembodiment, a rib 42C is located between each pair of lug bolt receivingholes 42B. Each of the ribs 42C is defined by a raised or embossed areawhich extends outwardly from or above the mounting surface 42 (bestshown in FIG. 12 in connection with the embodiment discussed therewith).The ribs 42C are operative to strengthen the mounting surface 42 to keepit from flexing during vehicle operation thereby improving the fatiguelife of the associated vehicle wheel. Alternatively, the spacing,location, number and/or configuration of the ribs 42C can be other thanillustrated and described if so desired.

[0060] Each of the spokes 44 includes an inner surface 44A and an outersurface 44B. The wheel disc 40 may also include one or more openings orwindows 46 formed in one or more of each of the spokes 44. In theillustrated embodiment, one of such windows 46 is provided in each ofthe spokes 44. Alternatively, the number and/or the location of thewindows 46 can be other than illustrated if so desired.

[0061] Each spoke 44 of the wheel disc 40 includes a generally flat rearor back wall 50, a pair of opposed side walls 52 and 54 extendingoutwardly from the rear wall 50, and an outermost end wall 56 extendingoutwardly from the rear wall 50 which defines a mounting flange. Theside walls 52 and 54 are operative to connect the associated spoke 44 tothe wheel mounting surface 42 thereof. In the illustrated embodiment,the side walls 52 and 54 extend generally radially inwardly ornon-parallel to one another and define a non-uniform or varying spokewidth therebetween. Alternatively, the structure of one or both of thespoke side walls 52 and 54 can be other than illustrated if so desired.

[0062] The mounting flange 56 includes an inner surface 56A and an outersurface 56B. The mounting flange 56 of each spoke 44 is connected to therear wall 50 by a transition portion 58. The transition portion 58 has agenerally curved or rounded profile which generally corresponds to theprofile of the adjacent outer surface 28A of the wheel rim 20 to whichit is joined. The inner surface 56A of the mounting flange 56 of thespoke 44 and the outer surface 28A of the rim 20 define a first disc torim interface area, indicated generally at A1, and an inner surface 58Aof the transition portion 58 and the outer surface 26A of the rim 20define a second disc to rim interface area, indicated generally at A2.Preferably, there is full or complete contact between the inner surface56A of the mounting flange 56 of the spoke 44 and the outer surface 28Aof the rim 20 at the first disc to rim interface area A1, and there isalso full contact between the inner surface 58A of the transitionportion 58 and the outer surface 26A of the rim 20 at the second disc torim interface area A2. However, due to manufacturing tolerances and/orother design specifications, there may be less than full contact at oneor both of the interface areas A1 and A2. In the illustrated embodiment,the mounting flange 56 of each spoke 44 is provided with a hole 56C fora purpose to be discussed below.

[0063] To assemble the vehicle wheel 10 in the illustrated embodiment, asuitable adhesive 60 is preferably first applied to the inner surface56A of each spoke 44. A suitable adhesive 60 is a one part epoxyavailable under the name BETAMATE® 4601, manufactured by Dow ChemicalCompany of Midland, Mich. Alternatively, the type and/or the applicationof the adhesive 60 can be other than illustrated and described if sodesired. For example, the adhesive 60 can be applied to the outersurface 28A of the rim 20.

[0064] Next, the wheel rim 20 and the wheel disc 40 are located relativeto one another in a predetermined position. In this position, the wheelrim outer surface 28A is disposed adjacent the spoke flange innersurface 56A and with the rim outer surface 26A disposed adjacent thespoke transition inner surface 48A. While in this position, the wheelrim holes 28C and the spoke flange holes 56C are preferably formed inthe rim 20 and spokes 44 at the same time by a suitable method, such asfor example, by piercing, drilling or laser cutting. Forming the holes28C and 56C in this manner ensures that the holes 28C and 56C are inproper alignment. Next, a suitable fastener 66 is installed in each ofthe aligned holes 28C and 56C to thereby join the wheel rim 20 and thewheel disc 40 together. Alternatively, the holes 28C and 56C can beseparately provided in one or both of the rim 20 and spokes 44 prior toassembly if so desired. As can be seen in FIG. 1, due to theconstruction of the wheel disc 40, the resultant wheel 10 has arelatively large opening 10A formed therein between each pair of thespokes 44.

[0065] In the illustrated embodiment, the fastener 66 is a rivet andincludes a generally round body 66A, an outer or head portion 66B, andan inner portion 66C. As best shown in FIG. 3, the holes 28C and 56C arepreferably countersunk holes so that when the rivet 66 is installed noportion of the rivet 66 protrudes outside of the respective surfaces 28Band 56B of the wheel rim 20 and the wheel disc 40. Alternatively, thetype, configuration, location and/or the number of fasteners 66 that areused can be other than illustrated if so desired. Also, as shown in thisembodiment, preferably the inner surface 58A of the transition portion58 and the outer surface 26A of the wheel rim well 26 abut or contactone another at the second disc to rim interface area A2; however, insome instances, depending upon the uniformity of the rim 20 and/or thedisc 40 or depending upon the particular vehicle wheel construction, theinner surface 58A and the outer surface 26A may not abut or contact oneanother along portions thereof or at all.

[0066] Referring now to FIG. 4 and using like reference numerals torefer to like parts, there is illustrated a portion of a secondembodiment of a method for joining the wheel rim 20 and the wheel disc40 together in accordance with the present invention. As shown therein,in this embodiment the adhesive 60 is provided at the first disc to riminterface area A1 and the rivet 66 is provided at the second disc to riminterface area A2 to thereby join the wheel rim 20 and the wheel disc 40together. To accomplish this, the well 26 of the rim 20 is provided witha plurality of holes 26B (only one of such holes 26B illustrated in FIG.4), and the wheel disc spoke 44 is provided with a like number of holes48A in the area of the transition portion 48 thereof.

[0067] Referring now to FIG. 5 and using like reference numerals torefer to like parts, there is illustrated a portion of a thirdembodiment of a method for joining the wheel rim 20 and the wheel disc40 together in accordance with the present invention. As shown therein,in this embodiment the adhesive 60 and the rivet 66 are provided at thefirst disc to rim interface area A1, and a weld 70 is provided at thesecond disc to rim interface area A2 to thereby join the wheel rim 20and the wheel disc 40 together.

[0068] Referring now to FIG. 6 and using like reference numerals torefer to like parts, there is illustrated a portion of a fourthembodiment of a method for joining the wheel rim 20 and the wheel disc40 together in accordance with the present invention. As shown therein,in this embodiment the adhesive 60 is provided at the first disc to riminterface area A1, and the rivet 66 is provided at both the first andthe second disc to rim interface areas A1 and A2 to thereby join thewheel rim 20 and the wheel disc 40 together. Alternatively, othercombinations of adhesive 60 and/or fasteners 66 and/or welds 70 can beused to join the disc 40 and the rim 20 together. For example, adhesive60 can be provided at the first disc to rim interface area A1, at thesecond disc to rim interface area A2, or at both the first disc to riminterface area A1 and the second disc to rim interface area A2; also, asuitable fastener 66 can be provided through associated holes in thefirst disc to rim interface area A1, through associated holes in thesecond disc to rim interface area A2, or through associated holes inboth the first disc to rim interface area A1 and the second disc to riminterface area A2.

[0069] Referring now to FIG. 7, there is illustrated a second embodimentof a rivet 80 which can be used to join the wheel rim 20 and the wheeldisc 40 together in accordance with the present invention. As showntherein, the rivet 80 includes a body 80A having a generally squarecross section.

[0070] Referring now to FIG. 8, there is illustrated a third embodimentof a rivet 82 which can be used to join the wheel rim 20 and the wheeldisc 40 together in accordance with the present invention. As showntherein, the rivet 82 includes a body 82A having a generally rectangularcross section.

[0071] Referring now to FIG. 9, there is illustrated a fourth embodimentof a rivet 84 which can be used to join the wheel rim 20 and the wheeldisc 40 together in accordance with the present invention. As showntherein, the rivet 84 includes a body 84A having a generally triangularcross section.

[0072] Referring now to FIG. 10, there is illustrated a fifth embodimentof a rivet 86 which can be used to join the wheel rim 20 and the wheeldisc 40 together in accordance with the present invention. As showntherein, the rivet 86 includes a body 86A having a generally star shapedcross section.

[0073] Referring now to FIG. 21, there is illustrated a sixth embodimentof a rivet 87 which can be used to join the wheel rim 20 and the wheeldisc 40 together in accordance with the present invention. As showntherein, the rivet 87 includes a body 87A having a generally oval shapedcross section.

[0074] Referring now to FIG. 22, there is illustrated a fifth embodimentof a rivet 88 which can be used to join the wheel rim 20 and the wheeldisc 40 together in accordance with the present invention. As showntherein, the rivet 88 includes a body 88A having a generally footballshaped cross section.

[0075] Referring now to FIGS. 11 through 13, there is illustrated asecond embodiment of a vehicle wheel, indicated generally at 100,produced in accordance with the present invention. The vehicle wheel 100is illustrated as being a fabricated “bead seat attached” vehicle wheel.The fabricated bead seat attached vehicle wheel 100 includes a fullwheel rim 120 and an inner wheel disc 140 constructed in accordance withthe present invention and which are joined together by a method inaccordance with the present invention. The vehicle wheel 100 defines ahorizontal or longitudinal vehicle wheel axis X1.

[0076] The wheel rim 120 is a fabricated rim formed from a suitablematerial, such as for example, steel, aluminum or alloys thereof,magnesium, or titanium. The wheel rim 120 includes an inboard tire beadseat retaining flange 122, an inboard tire bead seat 124, a generallyaxially extending well 126, an outboard tire bead seat 128, and anoutboard tire bead seat retaining flange 130. The well 126 includes anouter surface 126A and the outboard tire bead seat 128 includes an outersurface 128A and an inner surface 128B. The outboard tire bead seat 128further includes a plurality of holes 28C (only two of such holes 28Cshown in FIG. 12), formed therein. As will be discussed below, the holes128C are formed by a suitable process, such as for example, by piercing,drilling, or laser cutting.

[0077] The wheel disc 140 is forged, cast, fabricated, or otherwiseformed from a suitable material, such as for example, steel, aluminum oralloys thereof, steel, magnesium, or titanium. The wheel disc 140includes a generally centrally located wheel mounting surface or portion142 and a plurality of outwardly extending spokes 144. In theillustrated embodiment, the disc 140 includes four of such spokes 144which are shown as being formed integral with the wheel mounting surface142. Alternatively, the number and/or the construction of the spokes 144can be other than illustrated if so desired. For example, the vehiclewheel 10 can include less than four spokes 144 or more than four spokes144 and/or the spokes 144 can be formed separate from the wheel mountingsurface 142 of the disc 140 and joined thereto by a suitable method.

[0078] The wheel mounting surface 142 is provided with a centrallylocated pilot aperture 142A and a plurality of lug bolt receiving holes142B circumferentially spaced around the pilot aperture 142A. In theillustrated embodiment, the wheel mounting surface 142 includes four ofsuch lug bolt receiving holes 142B which are preferably provided in thewheel mounting surface 142 “in line” with a respective one of each ofthe spokes 144. Alternatively, the number and/or the location of the lugbolt receiving holes 142B can be other than illustrated if so desired.The lug bolt receiving holes 142B receive lug bolts (not shown) and nuts(not shown) for securing the vehicle wheel 100 on an axle (not shown) ofthe vehicle. The mounting surface 142 further includes a plurality of“strengthening” ribs 142C provided therein. As best shown in FIG. 12,each of the ribs 142C is defined by a raised or embossed area whichextends outwardly from or above the mounting surface 142.

[0079] Each of the spokes 144 includes an inner surface 144A and anouter surface 144B. The wheel disc 140 may also include one or moreopenings or windows 146 formed in one or more of each of the spokes 144.In the illustrated embodiment, one of such windows 146 is provided ineach of the spokes 144. Alternatively, the number and/or the location ofthe windows 146 can be other than illustrated if so desired.

[0080] Each spoke 144 of the wheel disc 140 includes a generally flatrear or back wall 150, a first pair of opposed side walls 152A and 154A′extending outwardly from the rear wall 150, a second pair of opposedside walls 154A and 154A′ extending outwardly from the rear wall 150,and an outermost end wall 156 extending outwardly from the rear wall 150which defines a mounting flange. The first pair of side walls 152A and152A′ define “inner” side walls and are operative to connect theassociated spoke 144 to the wheel mounting surface 142 thereof. Thesecond pair of side walls 154A and 154A′ define “outer” side walls andare disposed between the respective inner side walls 152A and 152A′ andthe back wall 150.

[0081] In the illustrated embodiment, the inner side walls 152A and152A′ extends generally parallel to one another and the outer side walls154A and 154A′ extend radially outwardly in a “flared” or “belled”manner relative to the inner side walls 152A and 152A′, respectively, atpreselected angles A1 and A2 with respect to the inner side walls 152Aand 152A′. The angles A1 and A2 are illustrated as being generally thesame and are in the range from about 5 degrees to about 135 degrees. Inthe illustrated embodiment, the angles A1 and A2 are approximately 20degrees.

[0082] The inner side wall 152A extends a distance D3 from about a pointA to about a point B, and the outer side wall 154A extends a distance D4from about the point B to about the point C. The inner side wall 152A′extends a distance D3′ from about a point A′ to about a point B′, andthe outer side wall 154A′ extends a distance D4′ from about the point B′to about the point C′. In the illustrated embodiment, the distances D3and D3′ are generally the same, and the distances D4 and D4′ are aboutthe same. Also, in the illustrated embodiment, the distances D3 and D3′and the distances D4 and D4′ are about the same. Alternatively, one ormore of the distances D3, D3′, D4 and D4′ can be other than illustratedif so desired.

[0083] The inner side walls 152A and 152A′ define a first spoke width ordistance D1, and the outermost ends of the outer side walls 154A and154A′ define a second spoke width or distance D2 which is greater thanthe distance D1. Preferably, the distance D2 is at least 5 percentgreater than the distance D1. More preferably, the distance D2 is atleast 50 percent greater that the distance D1.

[0084] The mounting flange 156 includes an inner surface 156A and anouter surface 156B. The mounting flange 156 of each spoke 144 isconnected to the rear wall 150 by a transition portion 158. Thetransition portion 158 has a generally curved or rounded profile whichgenerally corresponds to the profile of the adjacent outer surface 128Aof the wheel rim 120 to which it is joined. The inner surface 156A ofthe mounting flange 156 of the spoke 144 and the outer surface 128A ofthe rim 120 define a first disc to rim interface area, indicatedgenerally at B1, and an inner surface 158A of the transition portion 158and the outer surface 126A of the rim 120 define a second disc to riminterface area, indicated generally at B2. Preferably, there is full orcomplete contact between the inner surface 156A of the mounting flange156 of the spoke 144 and the outer surface 128A of the rim 120 at thefirst disc to rim interface area B1, and there is also full contactbetween the inner surface 158A of the transition portion 158 and theouter surface 126A of the rim 120 at the second disc to rim interfacearea B2. However, due to manufacturing tolerances and/or other designspecifications, there may be less than full contact at one or both ofthe interface areas B1 and B2. In the illustrated embodiment, themounting flange 156 of each spoke 144 includes at least two holes 156Cfor a purpose to be discussed below.

[0085] To assemble the vehicle wheel 100 in the illustrated embodiment,the wheel rim 120 and the wheel disc 140 are located relative to oneanother in a predetermined positioned. In this position, the wheel rimouter surface 128A is disposed adjacent the spoke flange inner surface156A and the outer surface 126A disposed adjacent the spoke transitioninner surface 148A. While in this position, the wheel rim holes 128C andthe spoke flange holes 156C are preferably formed in the rim 120 andspokes 144 at the same time by a suitable method, such as for example,by piercing, drilling or laser cutting. Forming the holes 128C and 156Cin this manner ensures that the holes 128C and 156C are in properalignment. Alternatively, the holes 128C and 156 can be separatelyprovided in one or both of the rim 120 and spokes 144 prior to assemblyif so desired.

[0086] Following this, a suitable fastener 166 is installed in each pairof the aligned holes 128C and 156C provided in each of the spokes 144 tothereby join the wheel rim 120 and the wheel disc 140 together. In theillustrated embodiment, the fastener 166 is a rivet. The rivet 166 canbe of any suitable shape, such as that illustrated and described herein.Alternatively, the type, configuration, location and/or the number offasteners 166 that are used can be other than illustrated if so desired.Preferably, as illustrated, each spoke 144 has two fasteners 166installed therein to join the disc 140 and the wheel rim 120 together.Also, as shown in this embodiment, preferably the inner surface 158A ofthe transition portion 158 and the outer surface 126A of the wheel rimwell 126 abut or contact one another at the second disc to rim interfacearea B2; however, in some instances, depending upon the uniformity ofthe rim 120 and/or the disc 140 or depending upon the particular vehiclewheel construction, the inner surface 158A and the outer surface 126Amay not abut or contact one another along portions thereof or at all.Alternatively, an adhesive and/or a weld can be used at one or both ofthe first disc to rim interface area B1 and the second disc to riminterface area B2 if so desired. As can be seen in FIG. 11, due to theconstruction of the wheel disc 140, the resultant wheel 100 has arelatively large opening 100A formed therein between each pair of thespokes 144.

[0087] Referring now to FIGS. 14 through 17, there is illustrate a thirdembodiment of a fabricated vehicle wheel, indicated generally at 200,produced in accordance with the present invention. The vehicle wheel 200produced according to this invention is illustrated as being afabricated “bead seat attached” vehicle wheel. The fabricated bead seatattached vehicle wheel 200 includes a full wheel rim 220 and an innerwheel disc 240 which are constructed and joined together in accordancewith the present invention. The vehicle wheel 200 defines a horizontalor longitudinal vehicle wheel axis X2.

[0088] The wheel rim 220 is a fabricated rim formed from a suitablematerial, such as for example, steel, aluminum or alloys thereof,magnesium, or titanium. The wheel rim 220 includes an inboard tire beadseat retaining flange 222, an inboard tire bead seat 224, a generallyaxially extending well 226, an outboard tire bead seat 228, and anoutboard tire bead seat retaining flange 230. The well 226 includes anouter surface 226A and the outboard tire bead seat 228 includes an outersurface 228A and an inner surface 228B. The outboard tire bead seat 228further includes a plurality of holes 228C (shown in FIG. 15), formedtherein. As will be discussed below, the holes 228C can be formed by asuitable process, such as for example, by piercing, drilling, or lasercutting.

[0089] The wheel disc 240 is forged, cast, fabricated, or otherwiseformed from a suitable material, such as for example, steel, aluminum oralloys thereof, steel, magnesium, or titanium. The wheel disc 240includes a generally centrally located wheel mounting surface or portion242 and a plurality of outwardly extending spokes 244. In theillustrated embodiment, the disc 240 includes five of such spokes 244which are shown as being formed integral with the wheel mounting surface242. Alternatively, the number and/or the construction of the spokes 244can be other than illustrated if so desired. For example, the vehiclewheel 200 can include less than five spokes 244 or more than five spokes244 and/or the spokes 244 can be formed separate from the wheel mountingsurface 242 of the disc 240 and joined thereto by a suitable method.

[0090] The wheel mounting surface 242 is generally that portion of thedisc 240 which is bounded by a circle P. However, the mounting surface242 can be other than illustrated depending upon the particular wheelconstruction. The wheel mounting surface 242 is provided with acentrally located pilot aperture 242A and a plurality of lug boltreceiving holes 242B circumferentially spaced around the pilot aperture242A. In the illustrated embodiment, the wheel mounting surface 242includes five of such lug bolt receiving holes 242B which are preferablyprovided in the wheel mounting surface 242 “in line” with a respectiveone of each of the spokes 244. Alternatively, the number and/or thelocation of the lug bolt receiving holes 242B can be other thanillustrated if so desired. The lug bolt receiving holes 242B receive lugbolts (not shown) and nuts (not shown) for securing the vehicle wheel200 on an axle (not shown) of a vehicle. The mounting surface 242further includes a plurality of “strengthening” ribs 242C providedtherein.

[0091] Each of the spokes 244 includes an inner surface 244A and anouter surface 244B. The wheel disc 240 may also include one or moreopenings or windows 246 formed in one or more of each of the spokes 244.In the illustrated embodiment, one of such windows 246 is provided ineach of the spokes 244. Alternatively, the number and/or the location ofthe windows 246 can be other than illustrated if so desired.

[0092] Each spoke 244 of the wheel disc 240 includes a generally flatrear or back wall 250, a pair of opposed side walls 252 and 254extending outwardly from the rear wall 250, and an outermost end wall256 extending outwardly from the rear wall 250 which defines a mountingflange. The side walls 252 and 254 are operative to connect theassociated spoke 244 to the wheel mounting surface 242 thereof. In theillustrated embodiment, the side walls 252 and 254 extend generallyparallel to one another and define a uniform or unvarying spoke widththerebetween. Alternatively, the structure of one or both of the spokeside walls 252 and 254 can be other than illustrated if so desired.

[0093] The mounting flange 256 includes an inner surface 256A and anouter surface 256B. The mounting flange 256 of each spoke 244 isconnected to the rear wall 250 by a transition portion 258. Thetransition portion 258 has a generally curved or rounded profile whichgenerally corresponds to the profile of the adjacent outer surface 228Aof the wheel rim 220 to which it is joined. The inner surface 256A ofthe mounting flange 256 of the spoke 244 and the outer surface 228A ofthe rim 220 define a first disc to rim interface area, indicatedgenerally at C1, and an inner surface 258A of the transition portion 258and the outer surface 226A of the rim 220 define a second disc to riminterface area, indicated generally at C2. Preferably, there is full orcomplete contact between the inner surface 256A of the mounting flange256 of the spoke 244 and the outer surface 228A of the rim 220 at thefirst disc to rim interface area C1, and there is also full contactbetween the inner surface 258A of the transition portion 258 and theouter surface 226A of the rim 220 at the second disc to rim interfacearea C2. However, due to manufacturing tolerances and/or other designspecifications, there may be less than full contact at one or both ofthe interface areas C1 and C2. In the illustrated embodiment, themounting flange 256 of each spoke 244 is provided with a hole 256C (orholes) for a purpose to be discussed below.

[0094] As best shown in FIG. 17, the side wall 252 extends a totaldistance D from about a point E to about a point F. The point E islocated at the transition from the wheel mounting surface 242 to thespoke side wall 252, and the point F is located at the transition fromthe spoke side wall 252 to the end wall 256. Similarly, the side wall254 extend a total distance D′ from about a point H to about a point I.The point H is located at the transition from the wheel mounting surface242 to the spoke side wall 254, and the point I is located at thetransition from the spoke side wall 254 to the end wall 256.

[0095] The side wall 252 includes a generally flared or curvednon-uniform first or inner side wall portion 252A defined throughout adistance D1 from about the point E to about a point G, and a generallyuniform second or outer side wall portion 252B defined throughout adistance D2 from about the point G to about the point F. Similarly, theside wall 254 includes a generally flared or curved non-uniform first orinner side wall portion 254A defined throughout a distance D1′ fromabout the point H to about a point J, and a generally uniform second orouter side wall portion 254B defined throughout a distance D2′ fromabout the point J to about the point I.

[0096] The mounting surface 242 of the disc 240 includes a section,indicated generally at 260 and best shown in the top middle portion ofFIG. 17, which extends between each pair of spokes 244 between thepoints H and E. As shown in FIG. 16, the disc section 260 includes atransition or intermediate wall 260A and a front or outer wall 260B. Thetransition wall 260A is slightly curved and extends generally radiallyoutwardly with respect to back wall 242C of the mounting surface 242.The front wall 260B extends generally in the same plane or parallel withrespect to the back wall 242C of the mounting surface 242 although notperfectly parallel in this embodiment. Thus, it can be seen that thefront wall 260B extends or projects substantially in the same plane asthe mounting surface 242 of the disc 240 and then, at approximatelypoints E and H smoothly changes direction and extends generallyperpendicular to the mounting surface 242 so as to smoothly transform orblend into the side walls 252 and 254 of the spoke 244. Also, in thisembodiment, the points E and H of each spoke 244 are generally locatedalong the circle P.

[0097] As shown in FIG. 16, the intermediate wall 260A extends at anangle M relative to the mounting surface back wall 242C, and the frontwall 260B extends at an angle N relative to the mounting surface backwall 242C. The angle M is in the range from about 5 degrees to about 85degrees and the angle N is in the range from about 0 degrees to about 30degrees. In the illustrated embodiment, the angle M is preferably about65 degrees and the angle N is preferably about 5 degrees. Alternatively,and angles M and N can be other than illustrated if so desired.

[0098] To assemble the vehicle wheel 200 in the illustrated embodiment,a suitable adhesive (not shown) is preferably first applied to at leastthe outer surface 228A of the rim 220. Preferably, the adhesive isapplied around substantially the entire periphery of the outer surface228A of the wheel rim 220. Alternatively, the application of theadhesive can be other than described if so desired.

[0099] Next, the wheel rim 220 and the wheel disc 240 are locatedrelative to one another in a predetermined position. In this position,the wheel rim outer surface 228A is disposed adjacent the spoke flangeinner surface 256A and the rim outer surface 226A disposed adjacent thespoke transition inner surface 258A. While in this position, the wheelrim holes 228C and the spoke flange holes 256C are preferably formed inthe rim 220 and spokes 244 at the same time by a suitable method, suchas for example, by piercing, drilling or laser cutting. Forming theholes 228C and 256C in this manner ensures that the holes 228C and 256Care in proper alignment. Alternatively, the holes 228C and 256C can beseparately provided in one or both of the rim 220 and spokes 244 priorto assembly if so desired.

[0100] Following this, a suitable fastener 266 is installed in each ofthe aligned holes 228C and 256C to thereby join the wheel rim 220 andthe wheel disc 240 together. Alternatively, the type, configuration,location and/or the number of fasteners 266 that are used can be otherthan illustrated if so desired. Also, as shown in this embodiment,preferably the inner surface 258A of the transition portion 258 and theouter surface 226A of the wheel rim well 226 abut or contact one anotherat a second disc to rim interface area C2; however, in some instances,depending upon the uniformity of the rim 220 and/or the disc 240 ordepending upon the particular vehicle wheel construction, the innersurface 258A and the outer surface 226A may not abut or contact oneanother along portions thereof or at all. As can be seen in FIG. 14, dueto the construction of the wheel disc 240, the resultant wheel 200 hasrelatively large openings 200A formed therein between each pair of thespokes 244.

[0101] Referring now to FIGS. 18 through 20, there is illustrated aportion of a fourth embodiment of a wheel disc, indicated generally at340, for use in a vehicle wheel in accordance with the presentinvention. The wheel disc 340 is forged, cast, fabricated, or otherwiseformed from a suitable material, such as for example, steel, aluminum oralloys thereof, steel, magnesium, or titanium. The wheel disc 340includes a generally centrally located wheel mounting surface or portion342 and a plurality of outwardly extending spokes 344. In theillustrated embodiment, the spokes 344 are shown as being formedintegral with the wheel mounting surface 342. Alternatively, theconstruction of the spokes 344 can be other than illustrated if sodesired. For example, the spokes 344 can be formed separate from thewheel mounting surface 342 of the disc 340 and joined thereto by asuitable method.

[0102] The wheel mounting surface 342 is generally that portion of thedisc 340 which is bounded by a circle Q. However, the mounting surface342 can be other than illustrated depending upon the particular wheelconstruction. The wheel mounting surface 342 is provided with acentrally located pilot aperture 342A and a plurality of lug boltreceiving holes 342B circumferentially spaced around the pilot aperture342A. In the illustrated embodiment, the lug bolt receiving holes 342Bare preferably provided in the wheel mounting surface 342 “in line” witha respective one of each of the spokes 344. Alternatively, the locationof the lug bolt receiving holes 342B can be other than illustrated if sodesired. The lug bolt receiving holes 342B receive lug bolts (not shown)and nuts (not shown) for securing the associated vehicle wheel on anaxle (not shown) of a vehicle. The wheel disc 340 may also include oneor more openings or windows 346 formed in one or more of each of thespokes 344. In the illustrated embodiment, one of such windows 346 isprovided in each of the spokes 344. Alternatively, the number and/or thelocation of the windows 346 can be other than illustrated if so desired.

[0103] Each spoke 344 of the wheel disc 340 includes a generally flatrear or back wall 350, a pair of opposed side walls 352 and 354extending outwardly from the rear wall 350, and an outermost end wall356 extending outwardly from the rear wall 350 which defines a mountingflange. The side walls 352 and 354 are operative to connect theassociated spoke 344 to the wheel mounting surface 342 thereof.Preferably, the edges of the side walls 352 and 354 are coined.Alternatively, the structure of the spokes 344 can be other thanillustrated if so desired.

[0104] As best shown in FIG. 18, the side wall 352 extends a totaldistance Y from about a point R to about a point S. The point R islocated at the transition from the wheel mounting surface 342 to thespoke side wall 352, and the point S is located at the transition fromthe spoke side wall 352 to the end wall 356. The side wall 354 extends atotal distance Y′ from about a point U to about a point V. The point Uis located at the transition from the wheel mounting surface 342 to thespoke side wall 354, and the point V is located at the transition fromthe spoke side wall 354 to the end wall 356.

[0105] The side wall 352 includes a varying or non-uniform first orinner side wall portion 352A defined throughout a distance Y1 from aboutthe point R to about a point T, and a generally varying or non-uniformsecond or outer side wall portion 352B defined throughout a distance Y2from about the point T to about the point S. The side wall 354 includesa varying or non-uniform first or inner side wall portion 354A definedthroughout a distance Y1′ from about the point U to about a point W, anda generally varying or non-uniform second or outer side wall portion354B defined throughout a distance Y2′ from about the point W to aboutthe point V.

[0106] The mounting surface 342 of the disc 340 includes a section,indicated generally at 360 and best shown in the top middle portion ofFIG. 18, which extends between each pair of spokes 344 between thepoints R and U. As shown in FIG. 19, the disc section 360 includes atransition or intermediate wall 360A and a front or outer wall 360B. Thetransition wall 360A is slightly curled or rolled over and extendsgenerally radially outwardly with respect to back wall 342C of themounting surface 342. The front wall 360B is rolled over or curled so asto extend generally back toward the mounting surface 342.

[0107] Also, as shown in this embodiment, a portion of the inner sidewall portion 352A includes an outer wall 352A′ which is slightly curledover as shown in FIG. 20. Similarly, a portion of the inner side wallportion 354A includes an outer wall 354A′ which is slightly curled over.Thus, it can be seen that in the embodiment shown in FIGS. 18-20, thatthe mounting surface 342 of the disc 340 and at least portions of theside walls 352 and 354 of the spoke 344 include portions which extendsgenerally parallel with respect the back wall 342A of the mountingsurface 342. In the embodiment shown in FIGS. 14 through 17, only themounting surface 242 of the disc 240 included portions which extendedgenerally parallel with respect the back wall 242A of the mountingsurface 242. In addition, in the embodiment shown in FIGS. 18 through20, such portions are further rolled over and extend back toward themounting surface 342. Alternatively, such portions in FIGS. 14 through17 could be rolled over such as in FIGS. 18 through 20.

[0108] Referring now to FIGS. 23-25, there is illustrated a fifthembodiment of a fabricated vehicle wheel, indicated generally at 410,produced in accordance with the present invention. The vehicle wheel 410produced according to this invention is illustrated as being afabricated drop center or well attached vehicle wheel. The fabricatedbead drop center vehicle wheel 410 includes a full wheel rim 420 and aninner wheel disc 440 which are constructed and joined together inaccordance with the present invention.

[0109] The wheel rim 420 is a fabricated rim formed from a suitablematerial, such as for example, steel, aluminum or alloys thereof,magnesium, or titanium. As shown in FIG. 25, the wheel rim 420 includesan inboard tire bead seat retaining flange 422, an inboard tire beadseat 424, a generally axially extending well 426, an outboard tire beadseat 428, and an outboard tire bead seat retaining flange 430. The well426 includes an inner surface 426A.

[0110] The wheel disc 440 is forged, cast, fabricated, or otherwiseformed from a suitable material, such as for example, steel, aluminum oralloys thereof, steel, magnesium, or titanium. The wheel disc 440includes a generally centrally located wheel mounting surface or portion442, a plurality of outwardly extending spokes 444, and an outer band orflange 447. In the illustrated embodiment, the disc 440 includes five ofsuch spokes 444 which are shown as being formed integral with the wheelmounting surface 442 and the outer flange 447. Alternatively, the numberand/or the construction of the spokes 444 can be other than illustratedif so desired. For example, the vehicle wheel 410 can include less thanfive spokes 444 or more than five spokes 444. Also, the spokes 444 andthe outer flange 447 can be formed integral with one another butseparate from the wheel mounting surface 442 of the disc 440 and joinedthereto by a suitable method.

[0111] The wheel mounting surface 442 is provided with a centrallylocated pilot aperture 442A and a plurality of lug bolt receiving holes442B circumferentially spaced around the pilot aperture 442A. In theillustrated embodiment, the wheel mounting surface 442 includes five ofsuch lug bolt receiving holes 442B which are preferably provided in thewheel mounting surface 442 in line with a respective one of each of thespokes 444. Alternatively, the number and/or the location of the lugbolt receiving holes 442B can be other than illustrated if so desired.The lug bolt receiving holes 442B receive lug bolts (not shown) and nuts(not shown) for securing the vehicle wheel 410 on an axle (not shown) ofa vehicle.

[0112] The mounting surface 442 further includes a plurality ofstrengthening ribs 442C provided therein. In the illustrated embodiment,a rib 442C is located between each pair of lug bolt receiving holes442B. Each of the ribs 442C is defined by a raised or embossed areawhich extends outwardly from or above the mounting surface 442. The ribs442C are operative to strengthen the mounting surface 442 to keep itfrom flexing during vehicle operation thereby improving the fatigue lifeof the associated vehicle wheel. Alternatively, the spacing, location,number and/or configuration of the ribs 442C can be other thanillustrated and described if so desired.

[0113] The wheel disc 440 may also include one or more openings orwindows 448 formed in one or more of each of the spokes 444. In theillustrated embodiment, one of such windows 448 is provided in each ofthe spokes 444. Alternatively, the number and/or the location of thewindows 448 can be other than illustrated if so desired. The outerflange 447 defines an annular mounting flange and includes an outersurface 447A.

[0114] To assemble the vehicle wheel 410 in the illustrated embodiment,the wheel rim 420 and the wheel disc 440 are located relative to oneanother in a predetermined position. In particular, the outer surface447A of the mounting flange 447 is positioned adjacent the inner surface426A of the well 426 of the wheel rim 420 and a weld 450 (shown in FIG.25) is applied to join the wheel disc 440 and the wheel rim 420 togetherto produce the fabricated well attached vehicle wheel. As can be seen inFIG. 23, due to the construction of the wheel disc 440, the resultantwheel 410 has a relatively large opening 410A formed therein betweeneach pair of the spokes 444. Also, while the wheel disc 440 is shown foruse in constructing a fabricated well attached vehicle wheel, the wheeldisc 440 could be used to produce other types of fabricated vehiclewheels. For example, the wheel disc 440 could be used to produce afabricated bead seat attached vehicle wheel or a fabricated full facevehicle wheel.

[0115] Referring now to FIGS. 26 and 27, there is illustrated a sixthembodiment of a fabricated vehicle wheel, indicated generally at 510,produced in accordance with the present invention. The vehicle wheel 510produced according to this invention is illustrated as being afabricated drop center vehicle wheel. In this embodiment, spokes 544 ofa wheel disc 540 are inverted or reversed compared to the spokes 444 ofthe wheel disc 440 of the vehicle wheel 410 illustrated in FIGS. 23-25.Thus, in this embodiment, the spokes 544 of the wheel disc 540 projectoutwardly as opposed to the spokes 444 of the wheel disc 440 whichproject inwardly.

[0116] Referring now FIG. 36, there is illustrated a block diagramshowing a sequence of steps for producing the first embodiment of thefull face fabricated vehicle wheel 10 of the present invention, asillustrated in FIGS. 1 and 2. Initially, in step 600, a flat sheet ofsuitable material, such as for example steel (not shown), is subjectedto a metal forming operation to produce an initial wheel disc blank 630,as shown in FIGS. 28 and 28A. The wheel disc blank 630 is a generallyround, flat disc blank and is preferably formed by a blanking orstamping operation. The wheel disc blank 630 preferably defines agenerally uniform wheel disc blank thickness T.

[0117] Next, in step 602, the wheel disc blank 630 is subjected to ametal forming operation to produce a finished wheel disc blank 640having a unique profile, as shown in FIGS. 29 and 29A. As shown therein,in the illustrated embodiment the finished wheel disc blank 640 includessix outwardly extending or protruding spoke portions 640A-640F which areequally spaced circumferentially about the wheel disc blank 640 and areidentical to one another. The wheel disc blank 640 is preferably formedby a blanking or stamping operation. Alternatively, the spacing, numberand/or configuration of the wheel disk blank 640 and/or the outwardlyextending spoke portions 640A-640F can be other than illustrated if sodesired. Also, the initial wheel disc blank 630 and/or the finishedwheel disc blank 640 can be formed by an other suitable processes if sodesired.

[0118] Following this, the finished wheel disc blank 640 is subjected toa metal forming operation to produce a generally “bubble” shaped wheeldisc preform 650 during step 604, as shown in FIGS. 30 and 30A. Thebubble shaped wheel disc preform 650 includes a generally flat innerportion 652 defined within a boundary of a first or inner circle C1, agenerally flat outer spoke portion 654 defined outside a boundary of asecond or outer circle C2, and an intermediate spoke portion 656 definedin the region between the first inner circle C1 and the second outercircle C2.

[0119] The intermediate portion 656 of the bubble shaped wheel discpreform 650 includes six raised or generally globe shaped portions656A-656F, and the outer portion 654 has six outwardly extendingportions 654A-654F. Each of the globe shaped portions 656A-656F define afirst radius R1 and a second radius R2 and extend from the flat innerportion 652 a distance A.

[0120] In the illustrated embodiment, the globe shaped portions656A-656F are equally spaced circumferentially about the bubble shapedwheel disc preform 650 and are identical to one another. Similarly, theouter spoke portions 654A-654F are equally spaced circumferentiallyabout the bubble shaped wheel disc preform 650 and are identical to oneanother. The bubble shaped wheel disc preform 650 is preferably formedby a stamping operation. Alternatively, the spacing, number and/orconfiguration of the bubble shaped wheel disc preform 650 and/or theglobe shaped spoke portions 656A-656F and/or the outwardly extendingspoke portions 654A-654F can be other than illustrated if so desired.

[0121] In step 606, the bubble shaped wheel disc preform 650 issubjected to a metal forming operation to produce a partially formedwheel disc 660, as shown in FIGS. 31 and 31A. As shown therein, thepartially formed wheel disc 660 has a desired shape or profile and ispreferably formed by a stamping operation. In particular, during step606, the spokes 44 of the finished wheel disc 40 begin to take shape andmaterialize in the partially formed wheel disc 660. Following this, instep 608, the partially formed wheel disc 660 is subjected to a metalforming operation to produce a wheel disc 670, as shown in FIGS. 32 and32A. To accomplish this, the wheel disc 660 is preferably restriked by astamping operation to produce the wheel disc 670. The wheel disc 670includes a generally “flattened” inner surface 672 and an outer annularportion 674.

[0122] Next, in step 610, the wheel disc 670 is subjected to a metalforming operation to produce a wheel disc 680 shown in FIGS. 33 and 33A.During step 610, a center pilot aperture 682 is formed in the wheel disc680, openings or windows 684 are formed in the wheel disc 680, andportions 686 are removed from the outer annular portion 674 of the wheeldisc 670. Preferably, the center hub hole 682 and the windows 684 areformed by a piercing operation and the portions 686 are removed by atrimming operation.

[0123] Following this, in step 612, the wheel disc 680 is subjected to ametal forming operation to produce a wheel disc 690, as shown in FIGS.34 and 34A. During step 612, the center pilot aperture 682 is furtherprocessed to produce the finished center pilot aperture 42A. Preferably,the finished pilot aperture 62A is formed by an extruding operation.Also, during step 612, the edge of the windows 684 are preferably coinedto produce the finished windows 46, and all the exposed edges of thewheel disc 680 are also preferably coined to remove any sharp edges fromthe wheel disc 690.

[0124] Next, the wheel disc 690 is subjected to final metal formingoperation in step 614 to produce the finished wheel disc 40, shown inFIGS. 1, 2, 35 and 35A, of the present invention. In particular, duringstep 614, the lug bolts receiving holes 42B are formed in the wheel disc40. Preferably, the lug bolt receiving holes 42B are formed by apiercing operation followed by a countersinking operation. As shown inFIGS. 35 and 35A, the finished wheel disc 40 includes the centrallylocated wheel mounting surface 42, the spokes 44, the pilot aperture42A, the lug bolt receiving holes 42B, and the openings 46. Followingthis, in step 616, the finished wheel disc 40 is joined to the wheel rim20 as described above to produce the finished fabricated vehicle wheel10. Alternatively, the number, type of metal forming and/or the sequenceof the steps 600-616 can be other than illustrated and described aboveif so desired.

[0125] In accordance with the provisions of the patent statutes, theprinciple and mode of operation of this invention have been describedand illustrated in its preferred embodiments. However, it must beunderstood that the invention may be practiced otherwise than asspecifically explained and illustrated without departing from the scopeor spirit of the attached claims.

What is claimed is:
 1. A fabricated vehicle wheel comprising: a wheelrim including an inboard tire bead seat retaining flange, an inner tirebead seat, a well, an outer tire bead seat, and an outboard tire beadseat retaining flange; a wheel disc joined to said wheel rim anddefining a wheel axis, said wheel disc including an inner wheel mountingpad, an outer annular rim connecting flange and a plurality of radialspokes connecting said inner wheel mounting pad to said rim connectingflange, said rim connecting flange extending solely in an axialdirection and welded to one of said outer tire bead seat and said wellof said wheel rim, said connecting flange defining a side edge surfaceextending between adjacent pairs of said spokes; and a plurality ofwindows formed in said wheel disc between adjacent pairs of said spokes,each of said windows having a predetermined shape defined by saidadjacent pairs of said spokes and said side edge surface of saidconnecting flange such that said window extends to an outermostperiphery of said wheel disc.
 2. The fabricated vehicle wheel accordingto claim 1 wherein each of said windows defines a radial line ofsymmetry.
 3. The fabricated vehicle wheel according to claim 1 whereineach of said spokes at the connection to said rim connecting flangedefines a spoke outermost circumferential dimension and each of saidwindows defines a window outermost circumferential dimension which isgreater than said spoke outermost circumferential dimension.
 4. Thefabricated vehicle wheel according to claim 1 wherein each of saidspokes includes a generally radially outwardly flared spoke portion. 5.The fabricated vehicle wheel according to claim 1 wherein at least onefastener extends through at least one hole of said rim and at least onehole of said wheel disc to join said wheel rim and said wheel disctogether.